Child resistant seamless lever-lid metal container

ABSTRACT

A container employs an access tool in child-resistant packaging. The container includes a seamless container body having a sidewall and a base formed of a single piece of metal. The container body is drawn to shape from the single piece of sheet metal via deep drawing. The container includes a lid that covers an aperture at an upper end of the container body when the container is closed, and a lever ring attached to the container body adjacent to an upper edge of the sidewall. The lever ring receives and grips a plug portion of the lid to cover the aperture. When not in use, the access tool is magnetically attached to the base, hidden from view. The access tool is a lever configured pry the lid away from the lever ring. The container may include a removably coupled secondary cover to cover the lever ring and lid.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation of U.S. application Ser. No. 17/342,264, filed Jun. 8, 2021, which claims benefit of U.S. Provisional Application No. 63/166,728, filed Mar. 26, 2021, both of which are incorporated herein by reference in their entirety.

TECHNICAL FIELD

The present disclosure relates generally to child-resistant packaging for the packaging and dispensing of articles, and more particularly to a child-resistant all-metal containers.

BACKGROUND

In the field of child-resistant packaging, there are many forms of safety closures designed to prevent or render it difficult for children to remove the closure from the packaging. Such safety closures are employed, for example, in containers that store medicines or other contents that might be harmful without supervision. Various types of child-resistant or safety containers have been developed that include a receptacle for storing contents and a lid that is locked in the closed position using some type of locking mechanism. Various child-resistant containers or safety containers require some manipulation of the closure that is not readily apparent before it can be removed from the associated container. Such containers can be relatively complex in construction and operation, and can require difficult manipulations of the closure for releasing the locking mechanism. Many of these safety containers, although child-resistant, have proven inconvenient and cumbersome to operate by users.

Some types of child-resistant closures, such as the child-resistant metal containers of the present disclosure, require an implement for removal. This category of child-resistant packaging requires a key device, coin, or other access tool to open the packaging and access contents. One advantage of the present disclosure, child-resistant packaging using tooled access, is that an access tool, although child-resistant, can be very convenient and easy to operate for the intended users providing an operational advantage over other safety container closures.

Many all-metal containers incorporate a container body formed by seaming ends of a metal sheet together to form a body sidewall. Completing the body requires spin-seaming a bottom to the previously formed body sidewall. All-metal containers of this type may be vulnerable to leakage or transfer of odors and air from the container body, e.g., due to the “lock seam” process of forming the body. While generally secure, the body seam and bottom seam are not impermeable.

SUMMARY

What is needed is an airtight child-resistant container that has a child resistant closure incorporating a tool designed for or otherwise suitable for opening a closure mechanism of the container. What is needed are child-resistant containers with safety factors based on the need to locate an access tool and the need to know how to use the tool to open the container and access its contents. What is needed are child-resistant containers with tool access that offers convenience for authorized users. What is needed is child-resistant all-metal containers that prevent odors and air from transferring in or out through the container body.

In an embodiment, a child-resistant container, comprises a container body, comprising a seamless member having a sidewall and a base formed of a single piece of metal, the base including a lower edge of the sidewall and a bottom surface; a lid configured to cover an aperture at an upper end of the container body when the container is closed; a lever member attached to the container body adjacent to an upper edge of the sidewall and defining the aperture, the lever member configured, when the container is closed, to receive and grip a plug portion of the lid to cover the aperture; and a lever tool configured, when in use, to abut against a portion of the lever member as fulcrum and to pry the lid away from the lever member and, further configured, when not in use, to be removably attached to the bottom surface.

In an embodiment, a child-resistant container comprises a container body comprising a seamless member having a sidewall and a base formed of a single piece of metal, the base including a lower edge of the sidewall and a bottom surface; a lid configured to cover an aperture at an upper end of the container body when the container is closed; a lever ring attached to the container body adjacent to an upper edge of the sidewall and defining the aperture, the lever ring configured, when the container is closed, to receive and grip a plug portion of the lid to cover the aperture; and a lever tool comprising an opener tool attached to or integral with a magnet, the lever tool configured, when in use, to abut against a portion of the lever ring as fulcrum and to pry the lid away from the lever ring and, further configured, when not in use, for the magnet to be magnetically adhered to the bottom surface.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure can be better understood by referring to the following figures. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the disclosure. In the figures, reference numerals designate corresponding parts throughout the different views.

FIG. 1 illustrates components of a child-resistant container with seamless straight-sided container body, according to an embodiment.

FIG. 2A illustrates a seamless, straight-sided container body with lever-lid cover, according to an embodiment.

FIG. 2B illustrates a seamless, straight-sided container with lever-lid cover closed, according to an embodiment.

FIG. 2C illustrates a stackable slip cover and a seamless, straight-sided container with lever-lid cover closed, according to an embodiment.

FIG. 2D illustrates a seamless, straight-sided container with stackable slip cover closed, according to an embodiment.

FIG. 3 illustrates components of a seamless child-resistant container with seamless convex container body with a straight neck portion with convex (embossed) ridges, according to an embodiment.

FIGS. 4A, 4B, 4C and 4D show stages of assembling a child resistant container with seamless convex container body, according to an embodiment.

FIG. 5 illustrates components of a child-resistant container with seamless fluted container body, with a straight neck portion with convex (embossed) ridges, according to an embodiment.

FIGS. 6A, 6B, 6C and 6D show stages of assembling a child resistant container with seamless fluted container body, with a straight neck portion with convex (embossed) ridges, according to an embodiment.

FIG. 7 shows a top view of a secondary convex step-up cover and a bottom view of a concave container base for a child-resistant container with seamless container body, according to an embodiment.

FIG. 8 is a perspective view of two stacked child-resistant containers with seamless container bodies, according to an embodiment.

FIG. 9 is a plan view of an access tool for a child-resistant lever lid container, according to an embodiment.

FIG. 10 is an elevation view of an access tool for a child-resistant lever lid container, according to an embodiment.

FIG. 11 is a perspective view of a child resistant container with a straight-sided seamless container body and lever lid, according to an embodiment.

FIG. 12 is a partial side elevation of a seamless container body and child-resistant opener device sectioned on a diameter of the container, according to an embodiment.

DETAILED DESCRIPTION

The present disclosure is here described in detail with reference to embodiments illustrated in the drawings, which form a part here. Other embodiments may be used and/or other changes may be made without departing from the spirit or scope of the present disclosure. The illustrative embodiments described in the detailed description are not meant to be limiting of the subject matter presented here.

Reference will now be made to the exemplary embodiments illustrated in the drawings, and specific language will be used here to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Alterations and further modifications of the inventive features illustrated here, and additional applications of the principles of the inventions as illustrated here, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention.

In many applications, reclosable containers are designed with child safety as a paramount consideration. Some types of child-resistant packaging, such as the child-resistant containers of the present disclosure, require an implement for removing a closure. This category of child-resistant packaging requires a key device, coin, or other tool to open the packaging and access contents. In the present disclosure, this category of child-resistant packaging is sometimes called tooled access, and the required tool is sometimes called an access tool. One advantage of child-resistant packaging using tooled access is that an access tool, although child-resistant, can be convenient and easy to operate for the intended users. Other characteristics of child-resistant packaging using tooled access are the need to house or store the access tool when not in use, and the need to locate the access tool when needed to open a closure. While these characteristics of tooled access can represent significant safety factors for child-resistant packaging, they offer ease of access for intended users.

One type of reclosable container is the lever lid tin, which has been widely employed in packaging of paint, coatings, powders and adhesives, as well as other products such as food products. The lever lid metal container tin of the present disclosure incorporates a child-resistant opener device. A lever lid metal container requires the use of an access tool to open it. The access tool is also herein called “lever tool” or simply “lever”. Commonly, the access tool is used to pry open the lever lid. The child-resistant metal container of the present invention makes use of the facts that children may be unable to locate a suitable access tool, and may encounter difficulties in using the tool. Specifically, in order to successfully lift the lid, the tool must initially have one end accurately positioned under the circumferential edge of the lid. Then, the tool must be pushed inwards (i.e., towards the center of the lid) to prevent the end slipping out, while the free end of the tool must be pulled down in order to lift the lid. Such action requires an understanding of fulcrums and leverage and may require a high level of dexterity, beyond the capability of many children.

Disclosed embodiments incorporate a container body comprising a seamless member having a sidewall and a base formed of a single piece of metal. The base including a lower edge of the sidewall and a bottom surface. Seamless container bodies according to this invention may be deep drawn to have the sidewall and a base drawn to shape from the single piece of metal. In various embodiments, a container body is drawn from a blank sheet metal, such as tinplate, electrolytic chromium coated steel (ECCS), or an aluminum alloy. Using a drawing and wall forming process, sheet metal is clamped and cut into circular blanks via a drawing machine. These blanks are then punched into cups during the initial drawing process.

Deep drawing may be accompanied by other forming techniques within a press. In an embodiment, a part is initially formed as a straight-sided seamless member, then with the use of a subsequent tool is expanded to a convex shape. In an embodiment, during forming, the part is provided with flutes dimensioned to provide the required outside dimension of the container body. Once the container body is formed, various post-processing steps are undertaken, including attaching a lever member, such as a lever ring, at the upper end of container body adjacent to an upper edge of the sidewall. The lever member may define an aperture at the upper end of container body, and the container may further include a lid configured to plug into and cover the aperture when the container is closed. Other post-processing steps may include coating the container body, e.g., to inhibit chemical reactions between the metal and container contents, and printing graphics onto the container body.

FIG. 1 illustrates components of a child-resistant container with seamless straight-sided container body. Components of child resistant container 100 include a seamless straight-sided container body 130, a domed lever lid 120, a magnetic lever tool 140, and an optional secondary cover 110. The secondary cover 110 may be a stacking slip cover.

FIG. 2A shows an all metal container with a seamless, straight-sided, air-tight body 220 and a domed, child-resistant lever-lid cover 210. A lever ring 230 is attached to a one piece (e.g., drawn) metal body 220. The lever ring 230 (or lever member or flange) defines a circular aperture 240. Lever-lid cover 210 with plug wall 250 is configured to plug into aperture 240. The structural configuration prevents odors and air from transferring in or out through the body because all air-transfer points (e.g., seams) have been eliminated. FIG. 2B shows child-resistant container 260 in closed configuration with lever lid cover plugged within the lever ring.

FIG. 2C shows a similar metal container configuration as FIGS. 2A, 2D, but with an added “slip cover” 270 to be fitted over the lever-lid plug cover of container 280. FIG. 2D shows the container 290 with slip cover 292 closed. One goal is to eliminate any possible air transfer occurring between the inner lever-lid and the ring construction. Additionally, the slip cover 292 is designed with step up profile or a convex (embossed) step 294 that creates an interlocking fit to a concave (debossed) base of container 290. This feature serves to securely stack two or more metal containers. Stacking is not otherwise possible with a metal container fitted with a lever-lid cover.

FIG. 3 shows a child resistant all metal container 300 generally similar to the container of FIG. 1, but with modified form of seamless container body 330. During forming of container body 330, a drawn straight-sided seamless body (which may be the same as or similar to container body 130) with the use of a subsequent tool is expanded into a convex body shape 340 and straight neck 350. In this configuration, the optional secondary cover 310 locks onto the neck with a twist motion (twist-on cover) rather than slipping over the body (slip-on cover).

FIG. 3 shows a secondary cover 310 with an “inside curled” sidewall, which is necessary to create the twist and lock feature. The straight neck 350 of container body 330 has embossed ridges that catch the inside curl of the lid sidewall and secure the metal container lid as it twists on tight. FIG. 3 shows the neck's embossed ridges 360 required for the twist-tight mechanism. FIGS. 4A-4D illustrate stages of assembling a seamless metal container with convex container body.

FIG. 5 shows a child resistant all metal container 500 generally similar to the container of FIG. 3, but with modified form of seamless container body 530. During forming of the container body 530, a drawn seamless body is formed in an axis-symmetric fluted configuration to create a fluted body shape 540. The convex container body has a straight neck portion 550. The neck portion 550 includes embossed ridges 560 for a twist-lock mechanism of secondary cover 510. FIGS. 6A-6D illustrate stages of assembling a seamless metal container with fluted container body.

FIG. 7 shows a top view of a secondary cover 720 for a child-resistant container with seamless container body. Secondary cover 720 is designed with step-up profile or a convex (embossed) step or platform 740. Additionally, FIG. 7 shows a bottom view of a container base 760 for a child-resistant container with seamless container body. Container base 760 has a concave (debossed) bottom surface 780 that creates an interlocking fit with the convex step 740 of secondary cover 720.

FIG. 8 is a perspective view of a container assembly 800 including two stacked child-resistant containers 820, 840. An embossed platform on the top of the secondary cover 860 of lower container 840 may be sized to fit securely inside a corresponding debossed area on the base 880 at underside of the upper container 820 to create a stable, non-slipping, secure stack when one container is placed on top of the other. Stacking is not otherwise possible with a metal container fitted with a lever-lid cover.

FIG. 9 is a plan view of an access tool 900 for a child-resistant lever lid container. Access tool 900 includes an opener device 920 in the form of a disc. Opener disc 920 has a flanged periphery or rim 930 and acts as a lever to remove the lid from the top of the container tin, e.g., by prying the lid from a lever ring. Additionally, opener device 920 includes a magnet 940 on one side of the opener tool, which is used to magnetically adhere the opener device 920 to the bottom of the container tin. In an example, opener device 920 is a circular disc with an outer diameter of 47 mm, and magnet 940 is a concentric circular cylinder of lower diameter than disc 920.

FIG. 10 is an elevation view of an access tool 1000 for a child-resistant lever lid container. The access tool includes an opener device 1020 in the form of a disc, and a magnet 1040 secured to an upper surface of the opener disc 1020. In an embodiment, magnet 1040 is permanently laminated or bonded to disc 1020. In an example, access tool 1000 has a total thickness of 3.24 mm, including a 2 mm thickness of opener tool 1020 and a 1 mm thickness of magnet 1040. In this example, disc 1020 has an outer diameter of 47 mm.

FIG. 11 is a perspective view of a cylindrical metal container 1100 with domed lever lid 1140 closed within an aperture lever ring 1120. The lever lid is also referred to herein as “lever-lid cover” or “simply “lid.” A plug wall of lever lid 1140 is dimensioned to provide a tight interference fit within a lid-receiving portion of lever ring 1120. The metal lever ring 1120 is relatively rigid during forcing of the lever lid 1140 into the lid-receiving portion, providing a child-resistant closure in which removal by hand is very difficult, if not impossible. To open the child-resistant container tin, a user who is aware of the hidden opener device 1150 can detach the device from the bottom of the tin. In an embodiment, the user inserts opener disc 1150 between the lever lid 1140 and lever ring 1120 to open the lid 1140. In an embodiment, the user rests the opener disc 1150 against an upper edge 1130 of container body 1110 as fulcrum and presses the rim of opener disc 1150 up against a flange 1150 of lever lid 1140 as lever to pry the lid 1130 open. If the lid 1130 is particularly tightly engaged within lever ring 1120, the user may progressively apply force at several points under the flange of the lid to permit removal of the lid.

FIG. 12 is a partial side elevation of a cylindrical metal container 1200. A child-resistant opener device 1250 is magnetically adhered at the bottom of the metal container. The container body 1210 includes a seamless sidewall 1214 and a base 1216 formed of a single piece of metal. The container base 1216 is debossed to create a recessed configuration in which a substantial percentage of the bottom surface 1256 of the base is out of contact with the planar surface that supports the container. Annular base surface 1244, also herein called annular support ring, serves as the container support and contacts the surface on which the container is placed. The drawing operation may create a smooth curve 1254 merging the container sidewall 1214 into the annular support ring 1244. The inner surface of the arcuate support ring may include an upwardly sloping surface 1246 adjacent to the inner wall of the annular support ring. A central portion of the bottom surface 1256 has a substantially flat disc-shaped section 1252 inset above the annular support ring 1244.

An opener device 1250 is magnetically adhered to central section 1252 via magnet 1258. In an embodiment, at least the bottom surface 1256 of metal container 1200 is formed of a ferromagnetic metal, or a paramagnetic metal that is magnetized in the presence of magnet 1258 to attract and retain the opener device 1250. In an embodiment, the one-piece container body 1200 is formed of tinplate steel, i.e., steel with a very thin coating of tin. In an embodiment, the one-piece container body 1200 is formed of chromium/chromium oxide coated steel (known as tin free steel (TFS)).

The lower edge of the container body 1210 including annular support ring 1244 extends beyond the bottom surface 1256, defining a recess 1248 below the bottom surface. The outer diameter of opener device 1250 (e.g., 47 mm) is well under the inner diameter of recess 1248 (e.g., 67 mm) so that opener device 1250 fits easily within the recess 1248. The vertical clearance provided by recess 1248 (e.g., 5 mm) is greater than the total thickness (e.g., 3.24 mm) of opener device 1250 including magnet 1258. As a result, opener device 1250 will not interfere with the container 1200 sitting level on the lower edge 1244 of container body 1210, and opener device 1250 will not be visible below the container.

In the embodiments of FIGS. 9-12, the container and the access tool are both circular. However, a lever lid with access tool can be implemented with any shape/size container (e.g., rectangle, square, round, oval, polygon). The lever lid itself can be generally round but the lever ring that it fits into can follow the shape of the container with just a round aperture in the middle for the actual lever lid. As used herein, “lever ring” may describe an annular or ring-shaped portion of the container, but also may have other shapes consistent with the shape of the container.

The foregoing method descriptions and the interface configuration are provided merely as illustrative examples and are not intended to require or imply that the steps of the various embodiments must be performed in the order presented. As will be appreciated by one of skill in the art, the steps in the foregoing embodiments may be performed in any order. Words such as “then,” “next,” etc., are not intended to limit the order of the steps; these words are simply used to guide the reader through the description of the methods. Although process flow diagrams may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a function, its termination may correspond to a return of the function to the calling function or the main function. 

1. A child-resistant container, comprising: a container body comprising a seamless member having a sidewall and a base formed of a single piece of metal, the base including a lower edge of the sidewall and a bottom surface, wherein the bottom surface is formed to define a substantially flat central portion inset above the lower edge of the sidewall; a lid configured to cover an aperture at an upper end of the container body to form a reclosable container; a lever member attached to the container body adjacent to an upper edge of the sidewall and defining the aperture, the lever member configured to receive and grip a plug portion of the lid to cover the aperture, wherein the lever member is configured to be removed by and a lever tool configured, when in use, to abut against a portion of the lever member as fulcrum and to pry the lid away from the lever member.
 2. The container of claim 1, wherein the bottom surface is further formed to define an upwardly sloping surface adjacent to the lower edge of the sidewall.
 3. The container of claim 1, wherein the lever tool is dimensioned to fit within a recess defined by the lower edge of the sidewall and the bottom surface.
 4. The container of claim 1, wherein the container body having the sidewall and the base is drawn to shape from the single piece of sheet metal via deep drawing.
 5. The container at claim 1, wherein the container has a circular cylindrical container body comprising one of a straight-sided seamless member and a straight-sided seamless member expanded to a convex shape.
 6. The container at claim 1, wherein the container has a circular cylindrical container body comprising a fluted seamless member.
 7. The container of claim 1, further comprising a secondary cover removably coupled to a portion of the sidewall adjacent to the upper edge of the sidewall to cover the lever member.
 8. The container of claim 7, wherein the secondary cover is removably coupled to the portion of the sidewall to cover the lever member as a slip cover.
 9. The container of claim 7, wherein the portion of the sidewall adjacent to the upper edge of the sidewall comprises a concave base portion, wherein the secondary cover includes a convex step that creates an interlocking fit to the concave base portion of the sidewall.
 10. The container of claim 1, wherein the container has a circular cylindrical container body, further comprising a secondary cover removably coupled to a portion of the sidewall adjacent to the upper edge of the sidewall via twist-lock connection to cover the lever member.
 11. The container of claim 7, wherein the bottom surface is further formed to define a debossed bottom surface that creates an interlocking fit with a convex step of the secondary cover.
 12. The container of claim 1, wherein the lever tool comprises an opener tool attached to or integral with a magnet and is configured to be removably attached to the substantially flat central portion of the bottom surface via magnetic attraction.
 13. The container of claim 1, wherein the container has a circular cylindrical container body and a circular bottom surface, the lever member comprises a lever ring, the lever tool comprises a circular disc, and the substantially flat central portion of the bottom surface is a disc-shaped section.
 14. The container tool of claim 1, wherein the lever tool has a flanged periphery or rim.
 15. A child-resistant container, comprising: a container body comprising a seamless member having a sidewall and a base formed of a single piece of metal, the base including a lower edge of the sidewall and a bottom surface; a lid configured to cover an aperture at an upper end of the container body; a lever ring attached to the container body adjacent to an upper edge of the sidewall and defining the aperture, the lever ring configured to receive and grip a plug portion of the lid to cover the aperture, wherein the lid is configured to be removed by a circular lever tool configured, when in use, to abut against a portion of the lever ring as fulcrum and to pry the lid away from the lever ring.
 16. The container of claim 15, wherein the bottom surface defines a recess at the lower edge of the sidewall and the bottom surface, and wherein the lower edge of the sidewall extends beyond the bottom surface, wherein the circular lever tool is dimensioned to fit within the recess.
 17. The container of claim 15, wherein the container body having the sidewall and the base is drawn to shape from the single piece of sheet metal via deep drawing.
 18. The container at claim 15, wherein the container has a circular cylindrical container body comprising one of a straight-sided seamless member, a straight-sided seamless member blown to a convex shape, and a fluted seamless member.
 19. The container of claim 15, further comprising a secondary cover removably coupled to a portion of the sidewall adjacent to the upper edge of the sidewall to cover the lever ring and lid via one of an interlocking connection, a twist-lock connection, and a slip cover.
 20. The container of claim 19, wherein the portion of the sidewall adjacent to the upper edge of the sidewall comprises a concave base portion, wherein the secondary cover includes a convex step that creates an interlocking fit to the concave base portion of the sidewall.
 21. The container of claim 1, wherein the lever tool is formed of a disc having a planar magnet on a side and a flanged periphery and is further configured, when not in use, to be removably attached to the substantially flat central portion of the bottom surface using the planar magnet.
 22. The container of claim 15, wherein the circular lever tool is formed of a disc having a planar magnet on a side and a flanged periphery and is further configured, when not in use, for the magnet to be magnetically adhered to the bottom surface. 